CALEFFI 5231 Series Guía

Low lead high-flow thermostatic mixing valves

NA10341.03

ASSE 1017

Function

The thermostatic mixing valve is used in systems producing domestic

hot water or in radiant heating systems. Its function is to maintain the

temperature of the mixed water supplied to the user at a constant set

value when there are variations in the supply pressure and temperature

of the incoming hot and cold water or in the ﬂow rate.

The 5231 series thermostatic mixing valves are ASSE 1017 approved for

point of distribution and are designed speciﬁcally for systems requiring

high flow rates and precise, stable temperature control. Optional

stainless steel inlet port check valves are available separately, for ﬁeld

installation only.

Product range

5231 series thermostatic mixing valve. NPT male and sweat union

connections, sizes 1", 1-1/4", 1-1/2", 2". Inlet port check valve s and

outlet temperature gauge optional.

Technical characteristics

Materials: - body: DZR low-lead brass (<0.25% lead content)

- shutter: PPSG40

- springs: stainless steel

- seals: peroxide-cured EPDM

- check valve extension (field installed): stainless steel

www.caleffi.com

5231 Series

INSTALLATION AND COMMISSIONING MANUAL

Suitable fluids: water, glycol solutions

Max. percentage of glycol: 30% glycol solution

Mixed temperature adjustment range: 95 – 150°F (32 – 66°C)

Temperature stability: ± 3°F (± 2°C)

Max. operating differential pressure (static): 200 psi (14 bar)

Max. operating differential pressure (dynamic): 75 psi (5 bar)

Hot water inlet temperature range: 120 – 195°F (49 – 91°C)

Cold water inlet temperature range: 39 – 80°F (3.9 – 26.6°C)

Max. inlet pressure ratio (H/C or C/H) for optimum performance: 2:1

Min. temp. difference between hot inlet and mixed outlet for optimum perf: 20°F (11°C)

Max. water hardness: 10 grains

Certified to:

1. ASSE 1017/CSA B125.3, certified by ICC-ES, file PMG-1357.

2. NSF/ANSI 372-2011, Drinking Water System Components-Lead Content Reduction of

Lead in Drinking Water Act, California Health and Safety Code 116875 S.3874, Reduction

of Lead in Drinking Water Act, certifed by ICC-ES, file PMG-1360.

CAUTION: All work must be performed by qualified personnel trained in the

proper application, installation, and maintenance of systems in accordance

with all applicable codes and ordinances.

SAFETY INSTRUCTION

This safety alert symbol will be used in this manual to draw attention to safety related instructions.

When used, the safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD.

CAUTION: If the thermostatic mixing valve is not installed, commissioned and

maintained properly, according to the instructions contained in this

manual, it may not operate correctly and may endanger the user.

CAUTION: Make sure that all the connecting pipework is water tight.

CAUTION: When making the water connections, make sure that the

pipework connecting the thermostatic mixing valve is not mechanically

over-stressed. Over time this could cause breakages, with consequent

water losses which, in turn, could cause harm to property and/or people.

CAUTION: Water temperatures higher than 100°F can be dangerous. During

the installation, commissioning and maintenance of the thermostatic mixing

valve, take the necessary precautions to ensure that such temperatures do

not endanger people.

Leave this manual for the user.

CAUTION: To prevent any damage which will cause the electronic mixing

valve to not operate correctly, treat highly aggressive water before entering the

thermostatic mixing valve.

ATTENTION: Lorsque vous effectuez les raccordements d'eau, assurez-vous

que la tuyauterie reliant le termostatico regolabile n'est pas mécaniquement

des overstressed. Au fil du temps, ceci pourrait causer des ruptures, avec

pour consequence des pertes en eau qui, à leur tour, peuvent causer des

dommages à la propriété et/ou les gens.

Ce symbole d'avertissement servira dans ce manuel à attirer l'attention sur la sécurité concernant

instructions. Lorsqu'il est utilisé, ce symbole signifie.

ATTENTION! DEVENEZ ALERTE ! VOTRE SÉCURITÉ EST EN JEU ! NE PAS SUIVRE CES

INSTRUCTIONS PEUT PROVOQUER UN RISQUE DE SECURITE.

ATTENTION: Tous les travaux doivent être effectués par du personnel

qualifié formé à la bonne application, installation et maintenance des systèmes

conformément aux codes et règlements locaux.

ATTENTION:Si le réducteur de pression, termostatico regolabile, n'est pas installé,

mis en service et entretenu correctement, selon les instructions contenues dans ce

manuel, il peut ne pas fonctionner correctement et peut mettre en danger l'utilisateur.

ATTENTION: S'assurer que tous les raccordements sont étanches.

ATTENTION: Les températures de l'eau supérieure à 100°F (38°C) peut

être dangereux. Au cours de l'installation, mise en service et l'entretien de

le réducteur de pression, le termostatico regolabile, prendre les precautions

nécessaires afin de s'assurer que de tells températures ne compromettent

pas les gens.

ATTENTION: Pour prévenir tout dommage qui provoque le mitigeur

électronique à ne pas fonctionner correctement, le traitement de l’eau très

agressive avant d’entrer dans la vanne de le termostatico regolabile.

CONSIGNE DE SÉCURITÉ

LAISSEZ CE MANUEL AVEC L’UTILISATEUR

Operating principle

A thermostatic mixing valve mixes hot and cold water in such a way as to maintain a constant set

temperature of the mixed water at the outlet.

A thermostatic element is fully immersed into the mixed water. It then contracts or expands causing

movement of the piston, closing either the hot or cold inlets, regulating the flow rates entering the

valve. If there are variations of temperature or pressure at the inlets, the internal element automatically

reacts attempting to restore the original temperature setting.

The Calefﬁ 5231 series mixing valves require a minimum temperature differential from hot inlet

to mixed water outlet of 20°F (11°C) to ensure the correct operation, and maximum pressure

difference between the hot and cold inlet parts no greater than 2:1 ratio. Softened water use is highly

recommended as the warranty is voided if used on water with hardness greater than 10 grains.

Control

The Caleffi 5231 series

mixing valves require a

minimum temperature

differential from hot inlet to

mixed water outlet of 20°F

(11°C) to ensure the correct

operation, and maximum

pressure difference

between the hot and cold

inlet parts no greater than

2:1 ratio. Softened water

use is highly recommended

as the warranty is voided

if used on water with

hardness greater than 10

grains.

Check valves ﬁeld installed only: code NA10366 for 1” & 1¼”

sizes; code NA10367 for 1½” & 2” sizes.

HOT

MIXED

COLD

HOT

MIXED

COLD

without inlet check valves

with inlet check valves (ﬁeld installed)

Flow curves

0.23

2.3

0.46

0.69

1.15

∆p (ft of head)

(l/s)(gpm)

4.6

6.9

11.5

0.1

0.2

0.3

0.5

(psi) (bar)

0.01

0.1

0.02

0.03

0.05

1.0

0.2

0.3

0.5

9.2

0.92 0.4

0.04

0.4

100

1.5

3.25

1” 1 1/2” 2”

1 1/4”

∆p



160

2.0

5.0

115

172

Flow should never exceed standards for pipe size and material.

Size

Connection

Model

Min.

Flow*

(GPM)

Max.

Flow*

(GPM)

1" NPT 523160A 4.4 40 7

1" Sweat 523168A 4.4 40 7

1 ¼" NPT 523170A 4.4 40 7.6

1 ¼" Sweat w/

temp gauge

523177A 4.4 40 7.6

1¼" Sweat 523178A 4.4 40 7.6

1 ½" NPT 523180A 8.8 70 13

1 ½" Sweat 523188A 8.8 70 13

2" NPT 523190A 8.8 70 14.2

2" Sweat 523198A 8.8 70 14.2

*Recommended ﬂow rates for temperature stabilty: ± 3°F (± 2°C).

Use

Calefﬁ 5231 series thermostatic mixing valves are designed to be installed at the hot water

heater and cannot be used for tempering water temperature at ﬁxtures as a point-of-use

valve. They are not designed to provide scald protection or chill protection service and

should not be used where ASSE 1070 devices are required. Wherever a scald protection

feature is required, ASSE 1070 certiﬁed mixing valves need to be installed. For safety

reasons, it is advisable to limit the maximum mixed water temperature to 120°F.

Instantaneous production of hot water

Calefﬁ 5231 series thermostatic mixing valves are designed for use on domestic water heaters that

have storage. The valve may deliver ﬂuctuating mixed temperatures when used on instantaneous

domestic water heaters.

Installation

Before installing a Calefﬁ 5231 series thermostatic mixing valve, the system must be inspected to

ensure that its operating conditions are within the range of the mixing valve, checking, for example,

the supply temperature, supply pressure, etc.

Systems where the Calefﬁ 5231 series thermostatic mixing valve is to be installed must

be drained and cleaned out to remove any dirt or debris which may have accumulated

during installation.

Failure to remove dirt or debris may affect performance and the manufacturer’s product

guarantee. Softened water use is highly recommended as the warranty is voided if used

on water with hardness greater than 10 grains.

The installation of ﬁlters of appropriate capacity at the inlet of the water from the mains

supply is always advisable.

In areas which are subject to highly aggressive water, arrangements must be made to

treat the water before it enters the valve.

Calefﬁ 5231 series thermostatic mixing valves must be installed in accordance with the diagrams

in this manual, taking into account all current applicable standards.

Calefﬁ 5231 series thermostatic mixing valves can be installed in any position, either vertical or

horizontal.

The following are shown on the mixing valve body:

- Hot water inlet, “H”.

- Cold water inlet, “C”.

- Mixed water outlet, unmarked.

In systems with thermostatic mixing valves, check valves must be installed to prevent undesirable

ﬂuid backﬂow. The 5231 series valves, codes listed in this instruction sheet, do not contain integral

check valves, so those must be sourced separately. Calefﬁ offers inlet port check valve assemblies

separately, for ﬁeld installation only to 5231 series valve.

It is essential that access to the valve is totally unobstructed for any maintenance which may be

required to the valve or connections. The piping from/to the valve must not be used to support the

weight of the valve itself.

Installation Tip

Scan to view

5231 MixCal

Locking the setting

Position the knob at the required value,

unscrew the top screw, slide off the knob and

put it back in such a way that the handle fits

into the internal slot of the knob. Tighten the

head screw

Index

Point

Dimensions

Sweat version

110 130

150

170

190

210

B B

Code A B C D E F Wt (lb)

523160A 1" NPT 4" 8" 7 5/8" 4 3/16" 3 3/8" 7.0

523168A 1" SWT 3 5/16" 6 5/8" 7" 3 1/2" 3 3/8" 7.0

523170A 1 1/4" NPT 4 1/8" 8 1/4" 7 3/4" 4 5/16" 3 3/8" 7.0

523177A 1 1/4" SWT 3 3/8" 6 3/4" 7 5/8" 4 1/8" 3 3/8" 9.0

523178A 1 1/4" SWT 3 3/8" 6 3/4" 7" 3 1/2" 3 3/8" 7.0

523180A 1 1/2" NPT 5 1/8" 10 1/4" 9 3/16" 5 7/16" 3 3/4" 17

523188A 1 1/2" SWT 4 1/16" 8 1/8" 8 1/8" 4 3/8" 3 3/4" 17

523190A 2" NPT 5 1/8" 10 1/4" 9 1/2" 5 3/4" 3 3/4" 18

523198A 2" SWT 4 5/16" 8 5/8" 8 5/8" 4 7/8" 3 3/4" 18

Setting the temperature

The temperature is set to the required value

by means of the adjusting knob with the

graduated scale on the top of the valve.

Pos. Min 1234567Max

T (°F) 95 104 109 117 122 129 136 142 150

T (°C) 35 40 43 47 50 54 58 61 66

with: THOT = 155°F (68°C) · TCOLD = 55°F (13°C) · PINLETS = 43 psi (3 bar)

Sweat version

110 130

150

170

190

210

B B

Code A B C D E F Wt (lb)

NA10366

1" NPT 5 1/2" 10 7/8" 7 5/8" 4 3/16" 3 3/8" 9.0

1" SWT 4 3/4" 9 1/2" 7" 3 1/2" 3 3/8" 9.0

1 1/4" NPT 5 5/8" 11 1/8" 7 3/4" 4 5/16" 3 3/8" 9.0

1 1/4" SWT 4 3/4" 9 5/8" 7 5/8" 4 1/8" 3 3/8" 11.0

1 1/4" SWT 4 3/4" 9 5/8" 7" 3 1/2" 3 3/8" 9.0

NA10367

1 1/2" NPT 7 3/8" 14 3/4" 9 3/16" 5 7/16" 3 3/4" 19

1 1/2" SWT 6 1/4" 12 5/8" 8 1/8" 4 3/8" 3 3/4" 19

2" NPT 7 3/8" 14 3/4" 9 1/2" 5 3/4" 3 3/4" 20

2" SWT 6 1/2" 13 1/8" 8 5/8" 4 7/8" 3 3/4" 20

Dimensions for 5231 models with ﬁeld installed inlet check valve assembles, code

numbers listed in ﬁrst column.

Dimensions with check valves

Replacement ttings

Code Description Tailpiece

all ports (3)

Inlet Check

Valve

Assembly (2)**

Outlet

adapter with

Temperature

Gauge**

Union

nuts (3)

Gaskets

(3)

523160A 1" MNPT union NA10009

NA10 366

NA10 476 R31589 R50057

523168A 1" Sweat union 31554 FD

523170A 1-1/4" MNPT union R416 60

523178A 1-1/4" Sweat union 41787 CST

523177A 1-1/4” Sweat union

with outlet temp. gauge*

41787 CST

(2 only)

R31589

(2 only

- 177A )

R50057

(2 only -

177A )

523180A 1-1/2” MNPT union 41371A

NA10 367 N A10461 R51838 R50060

523188A 1-1/2” Sweat union 41788 CST

523190A 2” MNPT union 41372A

523198A 2” Sweat union F0000496

*Replacement outlet mixed temperature gauge adapter complete with outlet tailpiece, union nut and gasket, and

temperature gauge (30-210°F), code NA10315.

**Field installed only

Replacement parts

Point of distribution mixed

temperature gauge adaptor ﬁts

high ﬂow 5231 series mixing

valves. Removable gauge ﬁts into

temperature well.

Gauge dial is 2" diameter and

scale from 30—210º F.

Low-lead brass body.

Code Description Lbs

NA10315 1¼" sweat with gauge 0.5

NA10476 For 1” & 1 ¼” * 3.0

NA10476 For 1 ½” & 2” * 4.0

688003A Replacement gauge with pocket well 0.2

R39591 Replacement temperature gauge 0.2

Inlet check valve assembly for

mounting on inlet union tail pieces

of 5231 mixing valves. Stainless

steel body, acetal plastic check

valve insert with NBR o-ring.

Code Description Open Pressure Lbs

NA10366 Check valve assembly 1” & 1¼" 0.23 psi 1.0

NA10367 Check valve assembly 1½" & 2" 0.20 psi 1.5

Replacement body.

Meets requirements of

ANSI/NSF 372-2011.

Certiﬁed to: ICC-ES listed to

ASSE 1017/CSA B125.3,

Low lead.

ASSE 1017

5231

Code Description Min. Flow (gpm) Cv Lbs

523179A 1½" union thread 4.4 7.6 5.0

523199A 2½" union thread 8.8 14.2 15.0

Includes no ﬁttings or union nuts.

* Requires separately ordered union nut, tailpiece and

union washer. See replacement ﬁttings table above.

Commissioning

After installation, the valve must be tested and commissioned in accordance with the instructions

given below, taking into account current applicable standards.

1) Ensure that the system is clean and free from any dirt or debris before commissioning the

thermostatic mixing valve. Be sure water hardness is less than 10 grains.

2) It is recommended that the temperature is set using a suitable calibrated digital thermometer.

The valve must be commissioned by measuring the temperature of the mixed water at the outlet.

3) The maximum outlet temperature from the valve must be set taking account of the ﬂuctuations

due to simultaneous use. It is essential for these conditions to be stabilized before commissioning.

4) Adjust the temperature using the adjusting knob on the valve. For safety reasons, it is advisable

to limit the maximum mixed water temperature to 120°F in domestic hot water systems.

Maintenance

Service tests should be carried out regularly to monitor the mixing valve performance, as deterioration

of performance could indicate that the valve and/or the system require maintenance. If, during

these tests, the temperature of the mixed water has changed signiﬁcantly in comparison with the

previous test, the details given in the installation and commissioning sections should be checked

and maintenance carried out.

The following aspects should be checked regularly to ensure that the optimum performance levels

of the valve are maintained. Every 12 months at least, or more often if necessary.

1) Check and clean the system ﬁlters.

2) Check that any non-return valves positioned upstream of the Calefﬁ valve are operating correctly,

without problems caused by impurities.

3) Limescale can be removed from internal components by immersion in a suitable de-scaling

ﬂuid.

4) When the components which can be maintained have been checked, commissioning should

be carried out again.

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